Outer case for non-aqueous electrolyte battery and method of producing the same

ABSTRACT

An outer casing of a non-aqueous electrolyte battery is capable of being mass-produced as well as thin and resistant to damage. The outer casing  4  comprises a casing body  4   a  and a cover  4   b . After being internally packaged, a non-aqueous electrolyte battery  2 , e.g. a lithium-ion polymer secondary battery, is sandwiched between the casing body  4   a  and the cover  4   b , which are then joined together integrally. The cover  4   b  is formed from a film-shaped sheet material  4   c  of a synthetic resin to make the outer casing  4  thin. The casing body  4   a  and the cover  4   b  have a casing body outer peripheral frame  9  and a cover outer peripheral frame  10 , respectively, formed by injection molding. Joint portions of the casing body  4   a  and the cover  4   b  have stepped portions  9   a  and  10   a , respectively. The stepped portions ensure the mechanical strength against shock and impact. With this structure, the outer casing  4  is resistant to damage.

TECHNICAL FIELD

The present invention relates to an outer casing for externallypackaging a non-aqueous electrolyte battery body packaged in an aluminumlaminated film or the like and also relates to a production method forthe outer casing. More particularly, the present invention relates to anouter casing of a non-aqueous electrolyte battery that externallypackages a non-aqueous electrolyte battery element with a thin casingbody formed of a synthetic resin or a film-shaped sheet material havinga frame member of a synthetic resin integrally fixed to the outerperiphery thereof. The present invention also relates to a productionmethod for the outer casing.

BACKGROUND ART

Conventionally, a lithium-ion battery is housed in a metal case, e.g. asteel can, or an aluminum can, and a polymer battery is packaged in analuminum laminated film. These batteries need to be further externallypackaged to protect them against shock from dropping or other externalimpact. There are known methods for externally packaging the batterybody, for example, a method wherein the battery body is hermeticallycovered with a case-shaped member formed of an aluminum sheet, a plasticmaterial, etc., and a method wherein the outer surface of the batterybody is covered with a thermoplastic resin by injection molding, therebypackaging the battery body in the molded resin.

It is also publicly known that heat-shrinkable tubing made of polyvinylchloride or the like is used as a heat-shrinkable synthetic resinmaterial for covering batteries. Stretched tubing made of a mixedcomposition consisting essentially of an olefin-based ionomer resin isalso publicly known as an example of heat-shrinkable tubing [forexample, see Japanese Patent Application Unexamined Publication (KOKAI)No. Hei 11-170365].

However, the conventional externally packaging methods have not yetsatisfied all the demands but still have many problems to be solved.Particularly, cellular phones and the like require as thin a battery aspossible, and a battery that meets the requirement has appeared. If thisbattery is covered with thin hear-shrinkable tubing, the tubing may bepartially wrinkled. Therefore, there is a problem in terms ofreliability in mass production of batteries of stable quality.Meanwhile, injection molding is excellent in mass productivity butdisadvantageous for the following reason. With the conventionalinjection molding, the flow of molten resin is deteriorated as thethickness of the molded part to be produced is reduced. Accordingly,there is a limit to the reduction of the part thickness.

Cellular phones and the like require a material having chemicalresistance and fire retardance. To prepare a resin material satisfyingthese requirements, PBT (polybutylene terephthalate) resin may be mixedwith a fire retardant consisting essentially of an inorganic material,for example. In this case, a part thickness of at least 0.3 mm to 0.4 mmis required because the flow of molten resin would otherwise bedeteriorated. Thus, it is even more difficult to obtain a thin moldedpart. Accordingly, the thickness of injection-molded parts cannot bereduced to less than a predetermined thickness as long as an injectionmolding method based on the presently common technique is employed.Lithium-ion polymer secondary batteries, in particular, arecharacterized by their capability of implementing a thin and lightweightstructure. Therefore, a thick outer casing that would lessen theadvantageous feature of lithium-ion polymer secondary batteries cannotbe adopted.

The outer casing for lithium-ion polymer secondary batteries is requiredto exhibit stable mechanical strength despite the thin and lightweightstructure. Meanwhile, there has been proposed a method of producing athin-walled molded part for housing an electronic component, wherein athin-walled portion of the molded part is formed of a film, and athick-walled portion thereof is formed by injection molding [JapanesePatent Application Unexamined Publication (KOKAI) No. 2002-283507].However, the thin-walled molded part does not completely cover the outersurface of the housed component. Therefore, it cannot be employed forthe above-described outer packaging of batteries.

DISCLOSURE OF THE INVENTION

With the above-described technical background, the present invention wasmade to attain the following objects.

An object of the present invention is to provide an outer casing of anon-aqueous electrolyte battery in which a side of the casing is formedfrom a film-shaped sheet material formed of a synthetic resin or byinjection molding, thereby realizing an extremely thin external packageexhibiting stable mechanical strength, and also provide a productionmethod for the outer casing.

Another object of the present invention is to provide an outer casing ofa non-aqueous electrolyte battery that is easy to manufacture andsuitable for mass production by injection molding process of highproductivity, and also provide a production method for the outer casing.

Still another object of the present invention is to provide an outercasing of a non-aqueous electrolyte battery that allows implementationof external packaging excellent in design, and also provide a productionmethod for the outer casing.

An advantage of the present invention is as follows. An outer casing ofa non-aqueous electrolyte battery is formed by joining together a casingbody and a cover that are different in configuration from each other, orby joining together a pair of mating molded pieces of the sameconfiguration. Joint portions for joining together the two constituentmembers of the outer casing are formed integrally on the two constituentmembers, respectively, in the form of a stepped structure. Therefore,the outer casing can be formed thin in thickness, and yet the requiredmechanical strength can be ensured satisfactorily.

Another advantage of the present invention is that the capacity-volumeefficiency and the capacity-weight efficiency of the battery pack can beimproved.

Still another advantage of the present invention is that the productionmethod for the outer casing can employ injection molding process that issimple and capable of mass production.

A further advantage of the present invention is that because a part ofthe outer casing can be formed by injection molding, the freedom ofconfiguration increases, so that the outer casing can be formed into aproduct that is tasteful and excellent in design.

The present invention adopts the following means to solve theabove-described problems.

An outer casing for externally packaging a non-aqueous electrolytebattery according to a first feature of the present invention is anouter casing (4) characterized by including a rectangular casing body (4a) formed of a synthetic resin for accommodating the non-aqueouselectrolyte battery. The casing body has a casing body outer peripheralframe (9) integrally provided on the outer peripheral edge of a side ofthe casing body. The outer casing (4) further includes a cover (4 b)including a film-shaped side panel (4 c) formed of a synthetic resinthat covers an open side of the non-aqueous electrolyte batteryaccommodated in the casing body (4 a). The cover (4 b) further includesa cover outer peripheral frame (10) formed of a synthetic resin that isintegrally fixed to the outer peripheral edge of the side panel (4 c).Further, the outer casing (4) includes joint portions for integrallyjoining together the casing body outer peripheral frame (9) and thecover outer peripheral frame (10) in opposed relation to each other.

It should be noted that the term “film-shaped” as used in the presentinvention means being in the form of a thin film, a thin plate, or asheet, but does not necessarily mean being a film.

An outer casing for externally packaging a non-aqueous electrolytebattery according to a second feature of the present invention ischaracterized as follows. In the outer casing according to the firstfeature of the present invention, the joint portions have positioningmeans (9 a and 10 a) for positioning the casing body outer peripheralframe (9) and the cover outer peripheral frame (10) relative to eachother.

An outer casing for externally packaging a non-aqueous electrolytebattery according to a third feature of the present invention ischaracterized as follows. In the outer casing according to the secondfeature of the present invention, the positioning means (9 a and 10 a)include a first stepped portion (9 a) with a stair-shaped sectionalconfiguration that is formed on the casing body outer peripheral frame(9) and a second stepped portion (10 a) with a stair-shaped sectionalconfiguration that is formed on the cover outer peripheral frame (10).The first stepped portion (9 a) and the second stepped portion (10 a)are fitted in opposed relation to each other and joined togetherintegrally.

An outer casing for externally packaging a non-aqueous electrolytebattery according to a fourth feature of the present invention ischaracterized as follows. In the outer casing according to the first orsecond feature of the present invention, the casing body (4 a) hasterminal windows (3) in the form of through-holes that allow contactwith input and output terminals of the non-aqueous electrolyte battery.

An outer casing for externally packaging a non-aqueous electrolytebattery according to a fifth feature of the present invention ischaracterized as follows. In the outer casing according to the thirdfeature of the present invention, the first stepped portion (9 a) andthe second stepped portion (10 a) each have surfaces differing in heightfrom each other.

A production method according to a sixth feature of the presentinvention is a method of producing the outer casing for externallypackaging a non-aqueous electrolyte battery according to the firstfeature of the present invention. The production method is characterizedin that the casing body (4 a) is formed by injection molding in aninjection-molding mold. The side panel (4 c) is inserted into aninjection-molding mold, and a synthetic resin is injected onto the outerperipheral edge of the side panel (4 c) to integrally fix the coverouter peripheral frame (10) to the outer peripheral edge of the sidepanel (4 c), thereby forming the cover (4 b). Then, the casing bodyouter peripheral frame (9) and the cover outer peripheral frame (10) areintegrally joined together in opposed relation to each other, therebyproducing the outer casing (4).

A production method for an outer casing of a non-aqueous electrolytebattery according to a seventh feature of the present invention ischaracterized as follows. In the production method according to thesixth feature of the present invention, the above-described fixing isfusion bonding by the molten resin for forming the cover outerperipheral frame (10) in the injection-molding mold, and theabove-described joining is effected by ultrasonic welding.

A production method for an outer casing of a non-aqueous electrolytebattery according to an eighth feature of the present invention ischaracterized as follows. In the production method according to theseventh feature of the present invention, welding portions (22) in theform of projections for the above-described joining are formed on thecasing body outer peripheral frame (9) and/or the cover outer peripheralframe (10) to effect the ultrasonic welding.

An outer casing for externally packaging a non-aqueous electrolytebattery according to a ninth feature of the present invention ischaracterized by including a film-shaped first side panel (44 e) formedof a synthetic resin that covers a side of the non-aqueous electrolytebattery that is wider than other sides of the battery. A film-shapedsecond side panel (44 c) formed of a synthetic resin covers a side ofthe non-aqueous electrolyte battery opposite to the above-describedside. A first outer peripheral frame (44 f) formed of a synthetic resinis integrally fixed to the outer peripheral edge of the first side panel(44 e). A second outer peripheral frame (44 d) formed of a syntheticresin is integrally fixed to the outer peripheral edge of the secondside panel (44 c). The outer casing further includes joint portions forintegrally joining together the first outer peripheral frame (44 f) andthe second outer peripheral frame (44 d) in opposed relation to eachother.

An outer casing for externally packaging a non-aqueous electrolytebattery according to a tenth feature of the present invention ischaracterized as follows. In the outer casing according to the ninthfeature of the present invention, the joint portions have positioningmeans (49 a) for positioning the first outer peripheral frame (44 f) andthe second outer peripheral frame (44 d) relative to each other.

An outer casing for externally packaging a non-aqueous electrolytebattery according to an eleventh feature of the present invention ischaracterized as follows. In the outer casing according to the tenthfeature of the present invention, the positioning means (49 a) includerecesses (49 a) and projections to be fitted into the recesses (49 a) toeffect positioning. The recesses (49 a) and the projections are formedon the first outer peripheral frame (44 f) and the second outerperipheral frame (44 d).

An outer casing for externally packaging a non-aqueous electrolytebattery according to a twelfth feature of the present invention ischaracterized as follows. In the outer casing according to the ninthfeature of the present invention, the first outer peripheral frame (44f) and/or the second outer peripheral frame (44 d) has terminal windows(43) in the form of through-holes that allow contact with input andoutput terminals of the non-aqueous electrolyte battery.

A production method according to a thirteenth feature of the presentinvention is a method of producing the outer casing for externallypackaging a non-aqueous electrolyte battery according to the ninthfeature of the present invention. The production method is characterizedin that the first side panel (44 e) is inserted into aninjection-molding mold, and a synthetic resin is injected onto the outerperipheral edge of the first side panel (44 e) to integrally fix thefirst outer peripheral frame (44 f) to the outer peripheral edge of thefirst side panel (44 e), thereby forming a first casing body member (44a). The second side panel (44 c) is inserted into an injection-moldingmold, and a synthetic resin is injected onto the outer peripheral edgeof the second side panel (44 c) to integrally fix the second outerperipheral frame (44 d) to the outer peripheral edge of the second sidepanel (44 c), thereby forming a second casing body member (44 b). Thefirst casing body member (44 a) and the second casing body member (44 b)are opposed to each other, and the first outer peripheral frame (44 f)and the second outer peripheral frame (44 d) are joined togetherintegrally.

A production method for an outer casing for a non-aqueous electrolytebattery according to a fourteenth feature of the present invention ischaracterized as follows. In the production method according to thethirteenth feature of the present invention, the above-described fixingis fusion bonding by the molten resin for forming the first outerperipheral frame and by the molten resin for forming the second outerperipheral frame in the respective injection-molding molds, and theabove-described joining is effected by ultrasonic welding.

A production method for an outer casing of a non-aqueous electrolytebattery according to a fifteenth feature of the present invention ischaracterized as follows. In the production method according to thefourteenth feature of the present invention, welding portions (22) inthe form of projections for the above-described joining are formed onthe first outer peripheral frame (44 f) and/or the second outerperipheral frame (44 d) to effect the ultrasonic welding.

It should be noted that the term “non-aqueous electrolyte battery” asused in the present invention means a battery containing a non-aqueouselectrolyte material in the electrolyte thereof. Examples of suchnon-aqueous electrolyte material include an electrolytic solution, apolymer gel electrolyte, a solid electrolyte, a polymer electrolyte, anda molten salt electrolyte. Batteries in the present invention includenot only secondary batteries but also primary batteries. Batteriescontaining a non-aqueous electrolyte material include lithium-ionbatteries, lithium-ion secondary batteries, lithium-ion polymerbatteries, etc.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an external view showing a lithium-ion polymer secondarybattery.

FIG. 2 is an exploded view illustrating the lithium-ion polymersecondary battery.

FIG. 3 is a sectional view taken along the line X-X in FIG. 1.

FIG. 4 is a sectional view taken along the line Y-Y in FIG. 1.

FIG. 5 is a sectional view of an injection-molding mold used to form acover.

FIG. 6 is a sectional view showing the injection-molding mold when it isclosed.

FIG. 7 is a fragmentary enlarged view of a cover outer peripheral framein the injection-molding mold.

FIG. 8 is a sectional view showing a molten resin injected into a cavityfor the cover outer peripheral frame.

FIG. 9 is a fragmentary sectional view of an outer casing after bondingprocess.

FIG. 10 is a sectional view showing the way in which the cover is joinedto the casing body by ultrasonic welding.

FIG. 11 illustrates an example showing another configuration of a sheetmaterial for forming a side of the casing.

FIG. 12 is a sectional view of a molten resin injected into a cavity foran outer peripheral frame, which shows a second embodiment.

FIG. 13 is a fragmentary sectional view of a cover after moldingprocess, which shows the second embodiment.

FIG. 14 is a sectional view of a thermoforming die for vacuum forming ina third embodiment.

FIG. 15 is a sectional view showing an injection-molding mold whenclosed in the third embodiment.

FIG. 16 is a sectional view of a cover after injection molding processin the third embodiment.

FIG. 17 is a sectional view showing an injection-molding mold whenclosed in a fourth embodiment.

FIG. 18 is a fragmentary enlarged view of the injection-molding mold inthe fourth embodiment.

FIG. 19 is a fragmentary enlarged view of a cover after injectionmolding process in the fourth embodiment.

FIG. 20 is a fragmentary enlarged view of a cover after injectionmolding process in a fifth embodiment.

FIG. 21 is a fragmentary enlarged view of a cover after injectionmolding process in a sixth embodiment.

FIG. 22 is a sectional view of an injection-molding mold used to form acover in a seventh embodiment.

FIG. 23 is a sectional view showing the injection-molding mold whenclosed in the seventh embodiment.

FIG. 24 is an external view showing a lithium-ion polymer secondarybattery having another configuration.

FIG. 25 is an exploded view illustrating the lithium-ion polymersecondary battery shown in FIG. 24.

BEST MODE FOR CARRYING OUT THE INVENTION

[First Embodiment]

A first embodiment of the present invention will be described below.FIG. 1 is an external view of a lithium-ion polymer secondary battery 1to which the present invention is applied. FIG. 2 is an exploded view ofthe lithium-ion polymer secondary battery 1. FIG. 3 is a sectional viewtaken along the line X-X in FIG. 1. FIG. 4 is a sectional view takenalong the line Y-Y in FIG. 1.

The lithium-ion polymer secondary battery 1 is a repeatedly rechargeablebattery, which is used as a battery for a cellular phone or the like.The lithium-ion polymer secondary battery 1 is a thin and lightweightbattery implemented by replacing an electrolytic solution with agel-state polymer electrolyte. In this example, the lithium-ion polymersecondary battery 1 is a thin battery (e.g. 3.8 mm in thickness)implemented so as to be usable in a cellular phone or the like.

An outer casing 4 of the lithium-ion polymer secondary battery 1 is asynthetic resin casing-produced by a method described later. The outercasing 4 basically comprises a casing body 4 a and a cover 4 b. Thecasing body 4 a of the outer casing 4 has three terminal windows 3 inthe form of through-holes through which an electric current is input andoutput. FIG. 2 is an exploded view of the lithium-ion polymer secondarybattery. A battery element 2 is a main body constituting the lithium-ionpolymer secondary battery.

The battery element 2 is formed by stacking a strip anode and a stripcathode with a polymer electrolyte layer and/or a separator interposedtherebetween, and winding the stack structure in the longitudinaldirection. In addition, an anode terminal 5 and a cathode terminal 6 areled out from the anode and the cathode, respectively. The anodecomprises a strip anode current collector and an anode active materiallayer formed thereon. Further, a polymer electrolyte layer is formed onthe anode active material layer. Further, a polymer electrolyte layer isformed on a cathode active material layer. The anode terminal 5 and thecathode terminal 6 are joined to the anode current collector and thecathode current collector, respectively. The materials and functions ofthese components are not directly related to the subject matter of thepresent invention. Therefore, a detailed description thereof is omitted.

The battery element 2 is packaged in an aluminum laminated film 7. Thealuminum laminated film 7 has a laminated structure formed from apolypropylene (PP) layer, an aluminum layer, a polyamide layer, etc.stacked in that order from the inner side. The aluminum layer preventswater from entering the interior of the battery. The polypropylene layerprevents change in quality of the polymer electrolyte and also serves asa joint surface of the aluminum laminated film 7. That is, joining forsealing the aluminum laminated film 7 is effected by fusion-bonding theopposed edges of the polypropylene layer.

The polyamide layer imparts strength and gas barrier properties to thealuminum laminated film 7. The aluminum laminated film 7 extends beyondthe outer periphery of the rectangular battery element 2 at three sidesthereof. That is, the aluminum laminated film 7 has a top hem portion 7a corresponding to the top position of the battery element 2 and sidehem portions 7 b corresponding to the side positions of the batteryelement 2. The top hem portion 7 a and the side hem portions 7 b areprovided by forming the fusion-bonded portions of the polypropylenelayer with an extra width at the three sides of the aluminum laminatedfilm 7 to prevent water from entering the interior of the batteryelement 2 from the outside. As shown in FIG. 2, the side hem portions 7b are folded in one direction when the battery element 2 is accommodatedin the outer casing 4.

The elongated strip anode and cathode terminals 5 and 6 are folded andlaminated to the top hem portion 7 a. A protective circuit board 8 isdisposed adjacently to the anode terminal 5 and the cathode terminal 6.The distal ends of the anode and cathode terminals 5 and 6 are connectedto respective terminals on the protective circuit board 8 by spotwelding, ultrasonic welding, etc., thereby being electrically connectedto each other. Because the protective circuit board 8 is accommodatedwithin the thickness of the battery element 2, together with the top hemportion 7 a, the lithium-ion polymer secondary battery 1 can be madecompact in size.

On the protective circuit board 8 are implemented a protective element,e.g. a thermostat, a PTC, or a temperature fuse, and/or an electroniccircuit for protection (not shown). Further, input/output terminals 8 aare provided on the protective circuit board 8, which are contactterminals for drawing an electric current. The input/output terminals 8a are capable of contacting terminals on the associated equipment thatare inserted from the terminal windows 3. Although in this example theterminal windows 3 are formed in a side of the casing body 4 a, theterminal windows 3 may be formed in another side that is at 90 degreesto the above-described side, for example, in the cover 4 b.Alternatively, the terminal windows 3 may be formed in a regionextending over from the casing body 4 a to the cover 4 b. The batteryelement 2 and the protective circuit board 8 are accommodated in thecasing body 4 a, which constitutes one casing half, and covered with thecover 4 b, which constitutes the other casing half.

The first embodiment of the present invention relates to theabove-described outer casing 4. That is, the outer casing 4 comprisesthe casing body 4 a and the cover 4 b, which are provided in the form oftwo casing halves, and the battery element 2 and the protective circuitboard 8 are sandwiched between the two casing halves, thereby beingpackaged. The completed lithium-ion polymer secondary battery 1 is aproduct in which the battery element 2 and the protective circuit board8 are packaged and integrated with the casing body 4 a and the cover 4b. The product name, the manufacturer name, etc. are indicated on thesurface of the outer casing 4 by using a label or the like.

Conventionally, a synthetic resin plastic molded casing has been used,as stated above. The synthetic resin casing can be produced with acomplicated configuration by injection molding. However, there is alimit to the reduction in thickness of the conventional synthetic resincasing. In contrast to this, the first embodiment of the presentinvention can fabricate a lightweight and thin outer casing having acomplicated configuration because of the use of a sheet material or acombination of a sheet material and injection molding process. Further,the first embodiment of the present invention has the advantage that themold structure is simplified, as will be explained later.

The outer casing 4 according to the present invention makes use of theadvantageous features of the material. That is, the casing body 4 a foraccommodating the lithium-ion polymer secondary battery 1 comprises asurface portion 9 b (side) injection-molded as thin as possible and acasing body outer peripheral frame 9 with a stepped portion 9 a thatforms the outer peripheral edge of the surface portion 9 b. The cover 4b opposed to the casing body 4 a comprises a sheet material 4 c (side)in the form of a film (thin film) of a synthetic resin and a cover outerperipheral frame 10 with a stepped portion 10 a that is formed byinjecting a synthetic resin to cover the outer peripheral edge of thesheet material 4 c. The casing body outer peripheral frame 9 of thecasing body 4 a and the cover outer peripheral frame 10 of the cover 4 bare opposed and joined to each other through the stepped portions 9 aand 10 a, thereby obtaining an outer casing 4 that is thin and yetmechanically strong and easy to manufacture.

An end portion inside the casing body 4 a may be integrally formed withboard supporting ribs for supporting the protective circuit board 8,according to need. In this embodiment, however, such ribs are not shownin the figure. It is a matter of course that the lithium-ion polymersecondary battery 1 is placed in the casing body 4 a so as not to bedisplaced. FIGS. 3 and 4 show the structure of the outer casing 4accommodating the battery element 2, which is a non-aqueous electrolytebattery, as stated above.

[Production Method for Outer Casing 4]

Next, a production method for the outer casing 4 will be described. Inthis embodiment, the casing body 4 a has an integral structure formed byinjection molding. That is, the surface portion 9 b for accommodatingthe battery element 2 and the casing body outer peripheral frame 9 aresimultaneously injection-molded in the same cavity to form an integralstructure. The casing body outer peripheral frame 9 of the casing body 4a is formed with a stepped portion 9 a having a stair-shaped sectionalconfiguration. The stepped portion 9 a may be provided with an undercutfor fitting. In this case, injection molding is performed by a publiclyknown method capable of removal from the mold by splitting the mold ormaking use of elastic deformation.

The injection molding method is based on a common method. Therefore, adescription thereof is omitted. The surface portion 9 b foraccommodating the battery element 2 is made as thin as possible withinthe range in which the mechanical strength required for the outer casing4 can be ensured. Meanwhile, the surface portion of the cover 4 b thatcovers the battery element 2 is formed of a sheet material 20 (stock forthe sheet material 4 c) in the form of a film (0.1 mm in thickness inthis example) of a synthetic resin, as shown in FIG. 5. One surface ofthe sheet material 20 may be previously printed with the specifications,trademark, etc. of the product or labeled to show such information.

Because the stock of the sheet material 20 is flat with a plane surface,the sheet material 20 before forming process can be easily printed withinformation indicating model name, capacity, place of manufacture, etc.or labeled to indicate such information instead of printing. The sheetmaterial 20 is formed of a synthetic resin. Examples of usable syntheticresins are PBT (polybutylene terephthalate), ABS resin, PC(polycarbonate), PET (polyethylene terephthalate), etc. In the firstembodiment, a sheet material 20 with a thickness of the order of from0.02 mm to 0.3 mm is used. As shown in FIG. 5, the rectangular sheetmaterial 20 is placed on a stationary mold member 11 of aninjection-molding mold by vacuum holding or other similar means.

Thereafter, a movable mold member 12 is moved toward the stationary moldmember 11 to press the sheet material 20, thereby plastically deformingit as shown in FIGS. 6 and 7. The plastically deformed sheet material 20is in the shape of a box with a tapered portion 21 around the outerperiphery thereof. The deformation of the tapered portion 21 of thesheet material 20 may cause wrinkle in the corner thereof. However, thewrinkled portion is softened and drawn to become unwrinkled by injectionof a molten resin to form the cover outer peripheral frame 10, asdescribed later. Therefore, there will be no problem.

As shown in FIGS. 6 and 7, a molten resin is injected into a sprue 13from the nozzle tip of an injection molding machine to form the coverouter peripheral frame 10. The injected molten resin flows through arunner 14 and a gate 15 to fill a cavity 16 for forming the cover outerperipheral frame 10. The filling of the injected molten resin causes thetapered portion 21 to extend and come in close contact with the cavitysurface of the movable mold member 12 as shown in FIG. 8. Thus, thecover outer peripheral frame 10 is constructed. The synthetic resin forforming the cover outer peripheral frame 10 is the same material as thatof the sheet material 20. That is, one of the above-described resins,i.e. PBT, ABS, PC, PET, etc. is used. It is preferable to use a resinmaterial that is excellent in chemical resistance and has a coefficientof thermal expansion close to that of the aluminum laminated film 7constituting the battery element 2. The reason for this is to allow thecover outer peripheral frame 10 to follow a change in size of thebattery element 2 even if the latter shrinks by heat.

As the result of filling the molten resin into the cavity 16, the moltenresin and the sheet material 20 fusion-bond to each other to form thecover outer peripheral frame 10, as has been stated above. To effect thedesired fusion bonding, it is preferable to use the same resin materialfor the cover outer peripheral frame 10 and the sheet material 20. Itshould be noted that injection molding as stated above is generallycarried out for a plurality of products simultaneously from theviewpoint of improving productivity. Therefore, in actual practice, themolten synthetic resin is simultaneously injected into not only thecavity 16 but also a plurality of other cavities (not shown) throughrespective runners 14. Thus, a plurality of covers 4 b aresimultaneously produced by injection molding.

The casing body 4 a has a thickness close to that of the battery element2. The casing body outer peripheral frame 9 of the casing body 4 a isprovided with terminal windows 3. Further, an end portion of the casingbody outer peripheral frame 9 of the casing body 4 a is provided with apositioning hole A or a positioning projection (cylinder) B. If theprojection B is provided on the casing body outer peripheral frame 9 ofthe casing body 4 a, the hole A is provided in the cover outerperipheral frame 10 of the cover 4 b. As has been stated above, thecasing body outer peripheral frame 9 and the cover outer peripheralframe 10 are molded on the respective outer peripheral edges of thecasing body 4 a and the cover 4 b. The joint portions of the casing bodyouter peripheral frame 9 and the cover outer peripheral frame 10 havethe stepped portions 9 a and 10 a, respectively. The casing body 4 a andthe cover 4 b are joined to each other through the stepped portions 9 aand 10 a.

The stepped portions 9 a and 10 a formed on the joint portions increasethe mechanical strength of the outer casing 4. FIG. 9 is a fragmentarysectional view showing the casing body 4 a and the cover 4 b after theyhave been joined to each other. As shown in FIG. 9, when a load F isapplied to the cover 4 b, because the joint portions have the steppedportions 9 a and 10 a, respectively, the mating casing body 4 a alsoreceives the load F through the stepped portions 9 a and 10 a.

Accordingly, the load F is borne at the joint portions and also borne atmutually abutting portions 9 c of the stepped portions 9 a and 10 a.Therefore, the joint strength is further increased in comparison to ajoint structure having joint portions that are flat over the entiresurfaces, for example. The structure according to the present inventionis free from the likelihood of breakage of the outer casing 4, e.g.separation of the cover 4 b from the casing body 4 a, even if animpacting load is applied to the outer casing 4 when it is dropped, forexample.

Welding portions (ridges) 22 for ultrasonic welding may be formed alongthe stepped portion 10 a of the cover outer peripheral frame 10 of thecover 4 b, according to need. The welding portions (ridges) 22 formed onthe joint portion increase the strength of joining with the matingmember and facilitate the joining. The welding portions 22 may beprovided on the joint portion of the mating member. The joint portionscan be joined together by fusion bonding even if they are flat. However,a joint portion with an uneven surface configuration is capable ofenhancing the joint strength.

Further, positioning of the casing body 4 a and the cover 4 b duringjoining process can be effected by fitting the stepped portions 9 a and10 a of the respective joint portions to each other. However, it ispreferable to employ a positioning structure in which pins (not shown)formed on the casing body 4 a are inserted into positioning holes formedin the protective circuit board 8 or the cover 4 b to join the casingbody 4 a and the cover 4 b to each other. With this structure, thecasing body 4 a and the cover 4 b, including the protective circuitboard 8, can be positioned with respect to each other.

FIG. 10 is a sectional view illustrating ultrasonic welding. The casingbody 4 a molded by the above-described method is inserted into apredetermined positioning recess 26 in a holder (fixing jig) 25, therebybeing positioned. The battery element 2 is mounted in the casing body 4a. Further, the cover 4 b is placed over the battery element 2 so as toface the casing body 4 a across the battery element 2.

In this state, a tool horn 27 secured to the distal end of a stationaryhorn 28, which is driven by an ultrasonic oscillator (not shown) of anultrasonic welding machine, moves downward to press a portion of thecover 4 b corresponding to the cover outer peripheral frame 10.Ultrasonic welding is based on the principle that ultrasonic vibrationis applied to the joint surfaces of two synthetic resins to weld themtogether by frictional heat.

More specifically, when the tool horn 27 being ultrasonically vibratedis brought into contact with one of two synthetic resin molded pieces tobe welded together, ultrasonic vibration energy transmitted from thedistal end of the tool horn 27 to the molded piece changes intomechanical vibration at the joint surfaces of the two molded pieces(this is known as “hammering effect”). Consequently, frictional heat isgenerated from the entire surfaces of the joint portions, causing theheated portions to be melted. Thus, the joint surfaces are weldedtogether instantaneously.

The welding portions 22 of the casing body 4 a are portions to bewelded, which are known as “ridges”. If ultrasonic energy isconcentrated on the welding portions 22, the rise in temperature of thejoint surface of the cover outer peripheral frame 10 is accelerated.Consequently, complete welding can be accomplished.

Thus, as shown in FIG. 10, the casing body 4 a and the cover 4 b arebutted against each other in the direction of the arrows, and thestepped portions 9 a and 10 a of the joint portions of the casing bodyouter peripheral frame 9 and the cover outer peripheral frame 10 arejoined to each other. The ultrasonic welding provides a beautifullyfinished joint and requires a short welding time. Ultrasonic welding canbe effectively applied to the outer casing 4 of the present inventionbecause it can be applied to small-sized products and carried outefficiently. With the ultrasonic welding, once the casing body 4 a andthe cover 4 b have been butt-joined together, they cannot bedisassembled. In actual practice, therefore, after the battery element2, the protective circuit board 8 and so forth have been incorporated,the casing body 4 a and the cover 4 b are butt-joined to form anintegral structure. FIG. 9 is a fragmentary sectional view of thebutt-joint portion of the outer casing 4 after the bonding process.

The figures illustrating the first embodiment are schematically drawnfor explanatory purposes. In actuality, the sheet material 20 and thecover outer peripheral frame 10 are extremely thin and very light inweight. External packaging by the outer casing 4 according to thepresent invention is mechanically strong because the outer casing 4 hasthe casing body outer peripheral frame 9 and the cover outer peripheralframe 10 and is provided with the stepped portions 9 a and 10 a. Theouter casing 4 also exhibits superior effects in terms of design.Accordingly, the lithium-ion polymer secondary battery 1 can be offeredas a product that is robust and exhibits a quality appearance.

Further, because labeling, printing, etc. can be easily performed on thecover 4 b even when it is in the stage of the sheet material 20, variousdesigns can be given to the outer casing 4. Moreover, productivity canbe increased. Although the sheet material 20 of the cover 4 b has itsouter peripheral edge folded during injection molding, as stated above,the sheet material 20 may be previously formed into a foldableconfiguration. FIG. 11 illustrates an example showing such aconfiguration of the sheet material. That is, the figure shows theoriginal configuration of a sheet material 4 c for forming a side of theouter casing 4. The sheet material 4 c has cut portions 23 at fourcorners and further has fold lines 24 thereon.

Because the cut portions 23 and the fold lines 24 have been formed onthe sheet material 20 a before it is inserted into the injection-moldingmold, the sheet material 20 a is easy to deform at the time of molding.Accordingly, it is possible to mold the outer casing 4 accurately.Further, in this embodiment, the cover member has its outer peripheralportion folded as shown in the figures. However, the cover member may bea plane sheet without being subjected to forming process. Next, anembodiment in which the cover member is a plane sheet will be described.

[Second Embodiment (Another Production Method for Outer Casing 4)]

FIG. 12 is a diagram showing a second embodiment, which is a fragmentarysectional view of an injection-molding mold used to mold a cover 4 b inthe second embodiment. In the foregoing first embodiment, after thesheet material 20 has been plastically deformed, the cover outerperipheral frame 10 is injection-molded. In the second embodiment shownin FIG. 12, the sheet material 20 does not extend to the outerperipheral portion of the cover outer peripheral frame 10. Accordingly,there is practically no deformation of the sheet material 20 in a cavity30. The second embodiment does not need trimming of the sheet material20 after the injection molding process and hence facilitatesmanufacture. FIG. 13 is a fragmentary sectional view of the cover 4 bafter the molding process.

[Third Embodiment (Thermoforming of Sheet Material)]

In either of the foregoing first and second embodiments, the sheetmaterial 4 c of the cover 4 b for forming a side of the outer casing 4is formed into a predetermined shape in the injection-molding mold. Inthis embodiment, the sheet material is thermoformed before it isinserted into the injection-molding mold. FIG. 14 is a sectional view ofa thermoforming die 25 a for vacuum forming. As shown in FIG. 14, asheet material 20 b, which is a thermoplastic sheet, is fixed on thethermoforming die 25 a and heated to soften with a heater 34. Thesoftened sheet material 20 b is sucked onto the thermoforming die 25 athrough a vacuum circuit 35 communicating with a vacuum device, therebyforming the sheet material 20 b.

Thereafter, the outer periphery of the thermoformed sheet material 20 bis trimmed with a cutting device (not shown). As shown in FIG. 15, thethermoformed and trimmed sheet material 20 b is inserted into aninjection-molding mold. Then, a molten resin is injected to flow througha runner 14 and a gate 15 and filled in a cavity 36 for molding a coverouter peripheral frame 10 in the same way as in the foregoingembodiments.

Thereafter, as shown in FIG. 16, an unnecessary portion at the outerperiphery of the sheet material 20 b is cut off with a cutting edge 29to complete the cover 4 b. It should be noted that the above-describedthermoforming process is vacuum forming, and the forming pressure is notmore than 1 atmospheric pressure. However, the thermoforming process maybe pressure forming process wherein the sheet material is formed byusing compressed air of the order of from 2 to 8 atmospheric pressures.

[Fourth Embodiment] (Thermoforming of Sheet Material)

A fourth embodiment is the same as the third embodiment in that thesheet material is thermoformed before it is inserted into aninjection-molding mold. The fourth embodiment is also the same as thethird embodiment in that the outer periphery of the thermoformed sheetmaterial 20 c is trimmed with a cutting device (not shown). As shown inFIG. 18, however, the thermoformed and trimmed sheet material 20 c hasburr 31 occurring on the cut surface as a result of the cutting process.

It is necessary to carry out a deburring step of removing the burr 31before or after ultrasonic welding performed with an ultrasonic weldingapparatus after the above-described injection molding. This embodimentenables the deburring step to be omitted. An outer peripheral portion 32of the sheet material 20 c constituting the cover outer peripheral frame10 is cut shorter than the thickness h (see FIG. 19) of the cover outerperipheral frame 10.

The outer peripheral portion 32 is positioned in a cavity 33 of aninjection-molding mold shown in FIG. 17. When a molten resin is injectedinto the cavity 33, the outer peripheral portion 32 of the sheetmaterial 20 c softens and fusion-bonds to the molten resin into anintegral structure (as shown in FIG. 19). Even if the sheet material 20c and the cover outer peripheral frame 10 are formed of different resinmaterials, the boundary between the sheet material 20 c and the coverouter peripheral frame 10 is indiscernible with the naked eye, providedthat the same coloring matter is used. Accordingly, the forming methodaccording to the fourth embodiment eliminates the need for the trimmingoperation otherwise required after the injection molding process andhence allows the number of steps to be reduced, advantageously.

[Fifth Embodiment] (Another Configuration of Stepped Portion)

FIG. 20 shows an example in which the stepped portion 9 a or 10 a at thejoint portion of the casing body 4 or the cover 4 b of the outer casing4 has a plurality of joint portions of different heights provided in astair-shaped configuration. The figure shows an example in which thecover 4 b has a stair-shaped stepped portion 10 a. However, the casingbody 4 a may also have a stair-shaped stepped portion 9 a. With thisarrangement, the joint area is enlarged, and the joint strength isincreased. An external force applied to the cover outer peripheral frame10 can also be borne by the casing body outer peripheral frame 9 of thecasing body 4 a in the same way as the above. Therefore, the outercasing 4 can be reinforced effectively.

[Sixth Embodiment] (Still Another Configuration of Stepped Portion)

FIG. 21 shows an example in which the stepped portion 9 a or 10 a of thejoint portion of the outer casing 4 has a slant surface. The figureshows an example in which the cover 4 b has a stepped portion 10 a witha slant surface. However, the casing body 4 a may also have a steppedportion 9 a with a slant surface. The slant surface is a special exampleof the configuration of the stepped portions 9 a and 10 a. However, anexternal force applied to the cover outer peripheral frame 10 can alsobe borne by the casing body outer peripheral frame 9 of the casing body4 a in the same way as the above-described example. Therefore, the outercasing 4 can be reinforced effectively.

[Seventh Embodiment] (Thermoforming for Obtaining Rounded SheetMaterial)

In the thermoforming of the sheet material in the first embodiment shownin FIGS. 5 to 8, the sheet material 20 is plastically deformed with arather large size in consideration of the fact that the whole deformedportion of the tapered portion 21 is fusion-bonded to the outerperipheral frame, as shown in FIGS. 5 to 8. In contrast to the firstembodiment, the sheet material 20 in this seventh embodiment, as shownin FIG. 22, has a smaller size than that of the sheet material 20 shownin FIG. 5.

Another feature of this embodiment resides in that a corner 12 a of amovable mold member 12 is intentionally rounded. When the sheet material20 vacuum-held to a stationary mold member 11 is pressed between thestationary and movable mold members 11 and 12 so as to be plasticallydeformed, the sheet material 20 becomes as shown in FIG. 23. After theplastic deformation, the outer peripheral portion 21 a of the sheetmaterial 20 is within the movable mold member 12 and will not extendoutward of the frame. The outer peripheral portion 21 a is rounded inconformity to the corner 12 a of the movable mold member 12.

A molten resin injected from a gate 15 through a sprue 13 and a runner14 is fusion-bonded to the outer peripheral portion 21 a in such amanner that the injected resin covers the whole outer peripheral portion21 a along the round profile of the corner 12 a of the movable moldmember 12 and has a stepped configuration. The outer peripheral portion21 a constitutes a corner of the outer casing 4 when completed and henceprovides a smoothly curved round configuration. With the roundconfiguration, the mechanical strength of the outer casing 4 can beenhanced. In terms of design also, the round configuration giveseffectively a smooth and soft appearance to the outer casing 4.

[Eighth Embodiment] (Another Lithium-Ion Polymer Secondary Battery)

FIG. 24 is an external view of a lithium-ion polymer secondary battery40 to which the present invention is applied. FIG. 25 is an explodedview of the lithium-ion polymer secondary battery 40. Theabove-described casing body 4 a shown in FIGS. 1 to 4 has the surfaceportion 9 b for accommodating the battery element 2 and the casing bodyouter peripheral frame 9, which are simultaneously molded into anintegral structure in the same cavity by injection molding.

The lithium-ion polymer secondary battery 40 shown in FIGS. 24 and 25has an outer casing 44 comprising a first casing body member 44 a and asecond casing body member 44 b prepared as a pair of casing body halvesthat are joined together into an integral structure. The first casingbody member 44 a and the second casing body member 44 b are produced bysubstantially the same production method as that for the casing body 4 ain the above-described first to eighth embodiments. Therefore, arepeated description of the structure and projection method concerningthe first and second casing body members 44 a and 44 b is omitted.

The first casing body member 44 a has a thin-walled, film-shaped firstside panel 44 e formed of a synthetic resin as stated above. A firstouter peripheral frame 44 f of a synthetic resin is molded on the outerperipheral edge of the first side panel 44 e by the above-describedinjection molding method and integrally fixed to the first side panel 44e in the mold. Similarly, the second casing body member 44 b has afilm-shaped second side panel 44 c formed of a synthetic resin. A secondouter peripheral frame 44 d of a synthetic resin is integrally formed onthe outer peripheral edge of the second side panel 44 c by injectionmolding.

The first outer peripheral frame 44 f and the second outer peripheralframe 44 d are opposed to each other and joined together into anintegral structure by ultrasonic welding, adhesive or other similarmeans. The first casing body member 44 a of the outer casing 40 hasthree terminal windows 43 in the form of through-holes, through which anelectric current is input and output. The second casing body member 44 bis formed with board supporting ribs 49, positioning holes 49 a, etc.Positioning pins of the second casing body member 44 b are inserted intothe positioning holes 49 a at the time of assembling. Therefore, thefirst casing body member 44 a and the second casing body member 44 b canbe assembled with high accuracy.

A battery element 42, a protective circuit board 48, an anode terminal45, a cathode terminal 46, etc. each have substantially the samestructure and function as in the case of the foregoing lithium-ionpolymer secondary battery 1. Therefore, a description thereof isomitted.

[Other Embodiments]

In the foregoing first to seventh embodiments, the sheet material 20 isprovided to extend outside the outer peripheral frame as a skin.However, the sheet material 20 does not always need to be disposedoutside the outer peripheral frame but may be disposed inside it.

INDUSTRIAL APPLICABILITY

The foregoing embodiments of the outer casing of the non-aqueouselectrolyte battery according to the present invention are applied to apolymer battery packaged in an aluminum laminated film. However, theouter casing of the present invention is also applicable to externalpackaging for a metal case, e.g. a steel can, or an aluminum can, whichhouses a lithium-ion battery.

1. An outer casing for externally packaging a non-aqueous electrolytebattery, comprising: a rectangular casing body (4 a) formed of asynthetic resin for accommodating said non-aqueous electrolyte battery,said casing body having a casing body outer peripheral frame (9)integrally provided on an outer peripheral edge of a side of said casingbody; a cover (4 b) including a film-shaped side panel (4 c) formed of asynthetic resin that covers an open side of said non-aqueous electrolytebattery accommodated in said casing body (4 a), and a cover outerperipheral frame (10) formed of a synthetic resin that is integrallyfixed to an outer peripheral edge of said side panel (4 c); and jointportions for integrally joining together said casing body outerperipheral frame (9) and said cover outer peripheral frame (10) inopposed relation to each other.
 2. An outer casing for externallypackaging a non-aqueous electrolyte battery according to claim 1,wherein said joint portions have positioning means (9 a and 10 a) forpositioning said casing body outer peripheral frame (9) and said coverouter peripheral frame (10) relative to each other.
 3. An outer casingfor externally packaging a non-aqueous electrolyte battery according toclaim 2, wherein said positioning means (9 a and 10 a) include a firststepped portion (9 a) with a stair-shaped sectional configuration thatis formed on said casing body outer peripheral frame (9) and a secondstepped portion (10 a) with a stair-shaped sectional configuration thatis formed on said cover outer peripheral frame (10), said first steppedportion (9 a) and said second stepped portion (10 a) being fitted inopposed relation to each other and joined together integrally.
 4. Anouter casing for externally packaging a non-aqueous electrolyte batteryaccording to claim 1 or 2, wherein said casing body (4 a) has terminalwindows (3) in the form of through-holes that allow contact with inputand output terminals of said non-aqueous electrolyte battery.
 5. Anouter casing for externally packaging a non-aqueous electrolyte batteryaccording to claim 3, wherein said first stepped portion (9 a) and saidsecond stepped portion (10 a) each have surfaces differing in heightfrom each other.
 6. A production method for an outer casing forexternally packaging a non-aqueous electrolyte battery as defined inclaim 1, said method comprising: forming said casing body (4 a) byinjection molding in an injection-molding mold; inserting said sidepanel (4 c) into an injection-molding mold and injecting a syntheticresin onto an outer peripheral edge of said side panel (4 c) tointegrally fix the cover outer peripheral frame (10) to the outerperipheral edge of said side panel (4 c), thereby forming said cover (4b); and integrally joining together said casing body outer peripheralframe (9) and said cover outer peripheral frame (10) in opposed relationto each other, thereby producing said outer casing (4).
 7. A productionmethod according to claim 6, wherein said fixing is fusion bonding bythe molten resin for forming said cover outer peripheral frame (10) insaid injection-molding mold, and said joining is effected by ultrasonicwelding.
 8. A production method according to claim 7, wherein weldingportions (22) in the form of projections for said joining are formed onsaid casing body outer peripheral frame (9) and/or said cover outerperipheral frame (10) to effect said ultrasonic welding.
 9. An outercasing for externally packaging a non-aqueous electrolyte battery, saidouter casing comprising: a film-shaped first side panel (44 e) formed ofa synthetic resin that covers a side of said non-aqueous electrolytebattery that is wider than other sides of said battery; a film-shapedsecond side panel (44 c) formed of a synthetic resin that covers a sideof said non-aqueous electrolyte battery opposite to said side; a firstouter peripheral frame (44 f) formed of a synthetic resin that isintegrally fixed to an outer peripheral edge of said first side panel(44 e); a second outer peripheral frame (44 d) formed of a syntheticresin that is integrally fixed to an outer peripheral edge of saidsecond side panel (44 c); and joint portions for integrally joiningtogether said first outer peripheral frame (44 f) and said second outerperipheral frame (44 d) in opposed relation to each other.
 10. An outercasing for externally packaging a non-aqueous electrolyte batteryaccording to claim 9, wherein said joint portions have positioning means(49 a) for positioning said first outer peripheral frame (44 f) and saidsecond outer peripheral frame (44 d) relative to each other.
 11. Anouter casing for externally packaging a non-aqueous electrolyte batteryaccording to claim 10, wherein said positioning means (49 a) includerecesses (49 a) and projections to be fitted into said recesses (49 a)to effect positioning, said recesses (49 a) and said projections beingformed on said first outer peripheral frame (44 f) and said second outerperipheral frame (44 d).
 12. An outer casing for externally packaging anon-aqueous electrolyte battery according to claim 9, wherein said firstouter peripheral frame (44 f) and/or said second outer peripheral frame(44 d) has terminal windows (43) in the form of through-holes that allowcontact with input and output terminals of said non-aqueous electrolytebattery.
 13. A production method for an outer casing for externallypackaging a non-aqueous electrolyte battery as defined in claim 9, saidmethod comprising: inserting said first side panel (44 e) into aninjection-molding mold and injecting a synthetic resin onto an outerperipheral edge of said first side panel (44 e) to integrally fix thefirst outer peripheral frame (44 f) to the outer peripheral edge of saidfirst side panel (44 e), thereby forming a first casing body member (44a); inserting said second side panel (44 c) into an injection-moldingmold and injecting a synthetic resin onto an outer peripheral edge ofsaid second side panel (44 c) to integrally fix the second outerperipheral frame (44 d) to the outer peripheral edge of said second sidepanel (44 c), thereby forming a second casing body member (44 b); andopposing said first casing body member (44 a) and said second casingbody member (44 b) to each other and integrally joining together saidfirst outer peripheral frame (44 f) and said second outer peripheralframe (44 d).
 14. A production method according to claim 13, whereinsaid fixing is fusion bonding by the molten resin for forming said firstouter peripheral frame and by the molten resin for forming said secondouter peripheral frame in the respective injection-molding molds, andsaid joining is effected by ultrasonic welding.
 15. A production methodaccording to claim 14, wherein welding portions (22) in the form ofprojections for said joining are formed on said first outer peripheralframe (44 f) and/or said second outer peripheral frame (44 d) to effectsaid ultrasonic welding.